Method of preparing a poultry product



3,413,127 METHOD OF PREPARING A POULTRY PRODUCT Donald V. Schwall, GlenEllyn, and Alan B. Rogers, Palos Park, Ill., assignors to Armour andCompany, Chicago, 11]., a corporation of Delaware N Drawing.Continuation-impart of application Ser. No. 354,118, Mar. 23, 1964. Thisapplication Aug. 29, 1966, Ser. No. 575,541

6 Claims. (Cl. 99-107) ABSTRACT OF THE DISCLOSURE A combination ofsodium chloride and edible phosphate salt is applied to the surface ofraw pieces of poultry, the pieces are agitated for a period of timeuntil the concentration of salt-soluble protein is formed on thesurfaces thereof, and the pieces are then pressed together to form aunitary body characterized by its improved resistance to water cook-outand its retention of intact slicability after cutting. It has been foundthat in the combination incorporaing the sodium chloride and phosphatesalts, the flavor characteristics of the two components are nonadditive,whereas the binding characteristics are intact additive, as a result ofwhich it is possible to use a high total salt concentration to obtainthe desired binding effect without imparting a noticeable sodiumchloride or phosphate taste.

This is a continuation-in-part of application Ser. No. 354,118, filedMar. 23, 1964, now Patent No. 3,285,753, issued Nov. 15, 1966.

The present invention relates to an improved method of preparing ashaped poultry product made up of a plurality of smaller pieces orchunks of poultry meat which are packed together in log, roll, roast orother form, and which can be cooked with relatively little cook-out ofnatural juices and can be sliced Without falling apart. The method ofthe present invention is directed specifically to the use of acombiantion of additives effective in producing an enhanced bindingeffect without impairment of flavor.

Usual commercial manufacturing procedures for heatprocessed meats incans, logs, or rolls result in considerable losses in water cook-out,which may amount to about 15-30% of the original Weight of the poultrymeat, varying with the heat treatment employed. Gelatin, wheat gluten,or other material are sometimes added to the formulation in an effort tohold this water and to hold the meat pieces together. However, theresults of such measures leave much to be desired. The poultry meat massis not continuous and contains gel pockets and layers between theindividual meat pieces. The gels not only fail to effectively hold themass together but are also undesirable from an aesthetic point of view.Moreover, the product usually lacks desired moistness and tenderness.

In copending application Ser. No. 352,325, filed Mar- 16, 1964, nowPatent No. 3,285,752, issued Nov. 15, 1966, there is described andclaimed the preparation of an improved poultry product which can becooked with relatively little cook-out of natural juices and which canbe sliced into continuous pieces which do not fall apart. Stated ingeneral terms, the process described in said copending applicationcomprises the steps of applying edible metallic salt, such as sodiumchloride, to the surfaces of pieces or chunks of poultry meat, agitatingor tumbling the said pieces or chunks until a concentration of saltsoluble protein is formed on the surfaces thereof, pressing the piecestogether, and then cooking. The agitation or tumbling of the poultrypieces in the presence of the salt causes salt soluble proteins, such asmyosin, to mi- United States Patent 0 grate to the surface of each pieceand to concentrate there in the form of a creamy, sticky coating. Whenthe pieces are pressed together in a container, this coating has anadhesive effect and binds the pieces together in a cohesive mass. Thiseffect is very much more pronounced after the product has been cooked,and in fact the pressed and cooked product is extremely similar inappearance, texture and sliceability to a single large piece of poultrymeat. The process of said copending application is particularlyapplicable to poultry meat which has passed through rigor mortis, or, inother words, has passed through the holding or aging period which isrequired in commercial operations to remove body heat and effect theaging necessary for tenderness in cooking. In copending application Ser.No. 354,118, there is described an improvement in which poultry skin isadded to the mixture to enhance the flavor and aroma of the productwithout impairing its 'adhesiveness.

The present invention is based in part on the discovery that theprocedures set forth in said copending applica tions Ser. No. 352,325and Ser. No. 354,118 can be substantially improved by utilizing acombination of sodium chloride and an edible phosphate salt, rather thana single salt component, as disclosed in said application. It has beenfound that in cases where a high degree of binding is desired but Wherethe higher salt concentrations necessary for such binding Would imparttoo strong a salt flavor to the poultry product, this difficulty can beovercome by utilizing part sodium chloride and part edible phosphate tomake up the total salt effect. It has been found that in a combinationincorporating substantial portions of sodium chloride and phosphatesalts, the flavor characteristics of the two components are non-additiveWhereas the binding characteristics are in fact additive, as a result ofwhich it is possible to use a high total salt concentration to obtainthe desired binding effect Without imparting a noticeable sodiumchloride or phosphate taste.

In its preferred embodiment, therefore, the process of the presentinvention comprises the steps of slaughtering and dressing poultry,applying to the surface of raw pieces of said poultry from 0.1 to 2.0%of sodium chloride based on the weight of said poultry pieces and from0.02 to 0.8% of an edible phosphate salt, agitating said pieces for aperiod of time until a concentration of salt soluble protein is formedon the surface thereof, and pressing the pieces together to form aunitary body characterized by its improved resistance to water cook-outand its retention of intact sliceability after cooking.

This invention is applicable generally to any type of poultry which isregularly slaughtered, processed and sold for its meat. The term poultryincludes turkeys, such as toms, hens, breeders, broilers, fryers, androasting turkeys; chickens, such as hens, roosters, broilers, fryers,and roasting chickens; ducks; geese; and the like. The invention appliesto the white and dark meat of poultry, as well as mixtures thereof, andit applies to poultry of any age, although the younger ages arepreferred. The benefits of the invention are not generally obtained withcured poultry products-Le. products which have been treated witheffective amounts of nitrites-and therefore poultry products which havebeen cured, in the ordinary sense of the word, are not included in thescope of the invention.

In preparing the poultry for use in the process, certain precautionsmust be observed. It is preferred that slush ice chilled poultry,brought down to a temperature below 40 F., be used. If instead it isdesired to use poultry which has been frozen immediately followingslaughter, it is preferred that the frozen bird be thawed inrefrigerated air not exceeding 40 F., or in running water not exceeding50 F., before using as raw material in the process. In either case, theprepared bird is boned in the normal manner, at temperatures preferablybelow 50 F., and the boned raw pieces and chunks used as startingmaterial in the process. The white and dark meat may b collectedseparately and used in the process separately if an all-white orall-dark end product is desired, or they may be combined in suitableproportions if a combination end product is desired. The smaller scrapsand trimmings and the skin are preferred to be collected separately andused in the process in the manner specifically described hereinafter.

The phosphate salt to be alllied, in combination with the sodiumchloride, to the surfaces of the poultry meat pieces or chunks, may beany edible phosphate salt which can combine with the natural moistureand the protein of the meat to result in a film of salt soluble proteinon the surface thereof. Generally speaking, the phosphate salts may beof any of the molecularly dehydrated sodium or potassium phosphateshaving the general formula M O.P O in which M is an alkali metal,particularly potassium or sodium, and in which the molar ratio of M to P0 is in the range of about 1:1 to about 2:1. Specific examples ofphosphate salts which may be used in the invention are sodiumtripolyphosphate (Na P O sodium hexametaphosphate (NaPO tetrasodiumpyrophosphate (Na P O tetrapotassium pyrophosphate (K P O potassiumtripolyphosphate (K P O and mixtures thereof.

It is preferred to use sodium chloride concentrations in the range of0.1 to 2.0% based on the weight of the poultry meat, and to usephosphate concentrations in the range of 0.02 to 0.8%. Ordinarily, theratio of sodium chloride to phosphate should be in the range of about1:1 to about 10:1, with a preferred ratio being about 3:1. It

is not necessary that the sodium chloride and phosphate be mixedtogether before applying to the surfaces of the poultry pieces. Suitableresults are obtained if they are applied either in a mixture orseparately, and in fact it is within the scope of the invention to applythe phosphate and salt at different stages of the poultry processing,prior to the agitation step. For example, the phosphate may be appliedto the while poultry carcasses while soaking in chilled water, prior toboning, and the sodium chloride applied to the cut-up pieces immediatelyprior to the agitation step. However, the preferred practice is tospread both the sodium chloride and the phosphate in dry form over thepieces of poultry meat prior to the agitation thereof.

After the salt and phosphate have been applied to the poultry pieces orchunks, the poultry is subjected to a mixing step. The mixture isagitated or tumbled for a short period of time until a concentration ofsalt-soluble protein is formed at the surface of each piece. Any type ofmixing, tumbling, or Working action which manipulates or rubs the saltonto or into the raw poultry meat surface is suitable. For example, thesalted poultry meat may be suitably agitated in a meat mixer of knowntype, although other obvious means of agitaiton such as churns, pumps,and the like may also be employed.

The temperature during the mixing step is preferably held below about 35F. Temperatures as high as 70 F. have been shown to give some effect,but by far the most efficient extraction of salt soluble protein takesplace at temperatures between about 25 and 35 F. Optimum temperaturesare 2830 F. The mixing is continued until each piece or chunk has becomesoft and pliable and is covered with a creamy coating of extracted saltsoluble protein. The mixing time can be as low as 5 minutes but isusually in the neighborhood of to minutes, with dark meat requiring asomewhat longer time than the white meat. Agitating the meat under avacuum or under reduced air pressure has been found beneficial ineliminating air holes from the final product. During the mixing step,other additives, such as sugar and spices in low concentrations, may beincluded without impairing the process.

After completion of the mixing procedure the poultry meat may be pressedtogether in containers such as casings or cans to provide conventionalforms of processed poultry meat such as rolls, logs, roasts, and thelike. For example, the meat from the mixing step may be placed in themold of a conventional type sausage stufiing machine and stuffed intoregular casings under pressure; or it may be pressed into cans or intocooking forms or other type pans for further processing. In any case itis desirable that pressure of some kind be applied to press the piecesof meat together and allow the adhesive nature of the salt solubleprotein coating to work for the formation of a cohesive mass.

The packed product is then cooked according to conventional practices,or it may be shipped or stored in raw form for cooking at a later time.It is not necessary for the purposes of the present specification todescribe in detail the conditions and techniques for the cooking step,since these are merely the usual practices of the industry. Generallyspeaking, and taking turkey rolls as an example, the product is cookedin cooking tanks to a final temperature in the range of 180 F. over aperiod of time amounting to about 30 minutes per pound of product.

The cooking step is effective in enhancing the binding properties of thesalt soluble protein and in blending the leaves or veins of protein intothe meat pieces themselves so that the end product has the appearanceand behavior of a unitary cohesive mass with the interleaved veins ofprotein barely discernible. Although the veins or striations caused bythe salt solution protein are very similar in color, strength, andbehavior to the main body of meat, and appear to blend thereinto, theirpresence nevertheless has a very significant effect, and the resultingcooked product is more juicy and tender.

In a further embodiment of the invention, it has been found that animproved product can be made by separately mixing poultry trimmings,scraps, skin, salt and phosphate to form a paste or comminuted batter,and then adding this paste or batter to the salted and phosphated rawpoultry pieces or chunks while the latter are being agitated in themixer in the main part of the process. It has been found that the skinprovides enhanced flavor and aroma to the end product and does notimpair the operability of the process. In fact, the paste or batter madefrom treated skin, trimmings, and scrap is found to enhance the flavorand appearance of the end product. In forming the paste or batter, it ispreferred to observe the same conditions with respect to salt andphosphate concentration, temperatures, and the like, as are used inpreparing the mixture of poultry pieces in the main part of the process.That is, it is preferred to add salt in concentrations within the rangefrom 0.8-1.5% and phos phate in concentrations of from .2 to .5 and towork at temperatures starting at 25-35 F. and not exceeding 7075 F. Itis important that the paste or batter not be added into the main processuntil after the raw poultry pieces or chunks have been treated with saltand phosphate and mixed for a period of time. Otherwise, the batterforms a coating on each piece or chunk of meat and inhibits or preventsthe salt and phosphate from coming in contact with the meat surfaces andtherefore substantially reduces the protein extraction effect. It ispreferred to agitate the treated raw poultry pieces or chunks for aperiod of at least 4 or 5 minutes before adding the batter, and toincorporate the paste in a proportion within the range of 10 to 35% ofpaste based on the total weight of the mixture.

The batter or paste described above may also include a portion of cookedpoultry meat. In the boning operation, it is sometimes desired to cutthe meat roughly from the bone and then cook the bones to achieve areadier separation of the more closely adhering pieces of meat Turkeyswere slaughtered, dressed, and slush ice chilled to a temperature of 35F. and held overnight. The chilled turkeys were then boned, keeping thetemperature of the meat below 50 F. during the entire procedure. In theboning operation, the breast meat was carefully removed by hand-boningand kept in a separate container. Dark meat was also removed from thethigh portion of the leg only and was also kept in a separate container.

pounds of raw, boneless white turkey meat obtained in this manner wereplaced in thin layers on clean trays and chilled in a freezer until thetemperature of the meat was brought down to 28-30 F. The 10 pounds ofwhite meat were then placed in a vacuum mixer, which was prechilled withice, and .1 pound of sodium chloride (1%) and .05 pound of anhydroussodium tripolyphosphate (.5 were sprinkled evenly over the surface ofthe meat. The mixer was operated for a period of minutes during whichtime the white meat became soft and pliable and covered with a creamy,sticky coating. The meat was taken from the mixer and placed in fibrouscasings and roasted in an oven at about 190 F. for a period of timecorresponding to minutes for each pound of product weight.

Another 10 pounds of the same raw, boneless white turkey meat wastreated in exactly the same way, except that .15 pound (1.5%) sodiumchloride was used and the phosphate was omitted.

After roasting, the two batches of product were sliced and evaluated.The product containing the phosphate had less of a salty flavor but atthe same time exhibited the same superior binding properties as theproduct containing no phosphate but a higher sodium chloride content.

EXAMPLE II 10 pounds of raw, boneless white turkey meat, obtained as inExample I, were brought to a temperature of 28-30" F. and placed in aprechilled vacuum mixer. .15 pound (1.5%) of sodium chloride and .08(18%) of sodium tripolyphosphate were added to the meat in dry form, andthe mixer was operated for 10 minutes, during which time the meat becamesoft and pliable and covered with a creamy, sticky coating.

The meat was taken from the mixer and placed in the mold of a sausagestuffing machine, and stuffed into a Visking No. 8 MP casing, clipped ateach end with metal clips. The roll was placed in a cooking tank in avertical position and cooked for 5% hours to a final internal meattemperature of 166 F., and was then cooled.

The resulting cooked product was sliced and evaluated and found to bevery securely bound together into a unitary body of white turkey meat.The flavor was acceptable, even though a total salt (sodium chlorideplus phosphate) concentration of 2.3% was incorporated in the product.If 2.3% sodium chloride alone or 2.3% sodium tripolyphosphate alone hadbeen incorporated, the product would have been unacceptable as beingeither too salty or as having too strong a phosphate taste.

EXAMPLE 1H Raw material preparation Turkeys were slaughtered, dressed,slush ice chilled to a temperature of 35 F., and boned. In the boningoperation, the breast meat was carefully removed by handboning, carebeing taken to remove all skin, excess fat, bruises, dark spots, bloodclots, pin feathers, gristle, and tendons, and the skin being placed ina separate container. Dark meat was removed carefully from the thighportion of the leg only, observing the same precautions as in the caseof breast meat. Wing knobs were removed and placed in a separatecontainer.

Raw meat chilling 756 pounds of boned white meat were placed in thinlayers on clean trays in a freezer for about 1 hour to Ibring thetemperature down to 2830 F.

Batter preparation 62 pounds of boneless scrap white meat and 62 poundsof skin were placed in a silent cutter, along with 2 pounds of a saltand spice mixture containing 50% sodium chloride, 31.4% brown sugar,14.7% sodium tripolyphosphate, 2.6% tetrasodium pyrophosphate, and 1.3%pepper, and the mixture was chopped for 5 minutes. The chopped batterwas rapidly chilled to 35 F.

Mixing The 756 pounds of white meat were placed in an Anco Vacuum Mixerwhich had been pre-chilled with ice, and 2 pounds 3 ounces of the samesalt and spice mixture previously added to the skin batter weresprinkled evenly over the surface of the meat. The mixer was operatedfor 5 minutes, and then 122 pounds of the batter were added and themixing continued for an additional 15 minutes. During the mixingoperation, a vacuum of 22 in. was maintained in order to prevent airholes in the end product.

The mixture was then taken from the mixer and placed in aluminumcontainers and roasted as in Example 'I. The roasted flavor and theslicing characteristics were excellent.

EXAMPLE IV Broiler chickens were slaughtered, dressed, and slush icechilled to a temperature of 35 F. according to conventional poultryprocessing procedures. The chilled broilers were then boned to collectdark and white meat in chunks and pieces.

300 pounds of boned, raw white meat thus obtained and 200 pounds ofboned, raw dark meat were spread in thin layers on clean trays in afreezer for approximately 1 hour to bring the temperature down to 2183OF., and the chilled meat was then placed in a pre-chilled Anco VacuumMixer and covered evenly with /2 pound edible grade sodiumhexametaphosphate and 6 pounds sodium chloride. The mixture was agitatedfor a period of 20 minutes, at the end of which time the pieces ofchicken had become soft and plia ble and covered with a layer of creamy,sticky material.

The treated mixture of white and dark chicken meat was then stuffed intoperforated casings and roasted in an oven at about F. for a period oftime corresponding to 25 minutes for each pound of product weight. Thechicken roasts prepared in this manner had an excellent flavor anddisplayed intact sliceability to a very desirable degree.

While in the foregoing specification this invention has been describedin relation to preferred embodiments thereof, and many details have beenset forth for the purpose of illustration, it will be apparent to thoseskilled in the art that many of the details set forth herein can bevaried considerably without departing from the basic principles of theinvention.

What is claimed is:

1. A method of preparing a poultry product comprising the steps ofslaghtering, dressing, and aging poultry, applying to the surface ofraw, uncured pieces of said poultry from .1 to 2.0% of sodium chloridebased on the weight of said poultry pieces and from 0.2 to 0. 8%

of an edible phosphate salt, agitating said pieces at a temperaturewithin the range of 25 to 70 F. until a concentration of salt solubleprotein is formed on the surface thereof, and pressing said piecestogether to form a unitary body characterized by its improved resistanceto water cook-out and its retention of intact sliceability aftercooking.

2. A method as set forth in claim 1 wherein the edible phosphate salt issodium tripolyphoshate.

3. A method as set forth in claim 1 wherein the edible phosphate salt issodium hexametaphosphate.

4. A method as set forth in claim 1 wherein the edible phosphate salt istetrasodium pyropnosphate.

5. A method as set forth in claim 1 wherein the sodium chloride andedible phosphate are spread in dry form over the said poultry piecesprior to agitation thereof.

6. A method of preparing a poultry product, comprising the steps ofslaughtering, dressing, and aging poultry, skinning and boning saidpoultry, applying sodium chloride and an edible phosphate salt to thesurfaces of raw, uncured pieces of said boned poultry, said sodiumchloride being applied in a concentration of about 0.1 to 2.0% and saidedible phosphate salt being applied in a concentration of about 0.02 to0.8% based on the final weight of the product, agitating said pieces ata temperature within the range of to 70 F. until a concentration ofsalt-soluble protein is formed on the surfaces thereof, thereaftermixing into said coated pieces a paste prepared by grinding poultry skinand small poultry pieces, said paste being incorporated in a proportionwithin the range of 10 to of paste based on the total weight of themixture, further agitating the mixture, and pressing said mixturetogether to form a unitary body characterized by its improved resistanceto water cookout and its retention of intact sliceability after cooking.

References Cited UNITED STATES PATENTS 3,024,113 3/ 1962 Torr 99-1073,049,428 8/ 1962 Hopkins et a1 99l07 X 3,076,713 2/ 1963 Maas 99'--107HYMAN LORD, Primary Examiner.

